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NASA NTRS1990

Ignition and combustion characteristics of metallized propellants

Research designed to develop detailed knowledge of the secondary atomization and ignition characteristics of aluminum slurry propellants was started. These processes are studied because they are the controlling factors limiting the combustion efficiency of aluminum slurry propellants in rocket applications. A burner and spray rig system allowing the study of individual slurry droplets having diameters from about 10 to 100 microns was designed and fabricated. The burner generates a near uniform high temperature environment from the merging of 72 small laminar diffusion flames above a honeycomb matrix. This design permits essentially adiabatic operation over a wide range of stoichiometries without danger of flashback. A single particle sizing system and velocimeter also were designed and assembled. Light scattered from a focused laser beam is related to the particle (droplet) size, while the particle velocity is determined by its transit time through the focal volume. Light from the combustion of aluminum is also sensed to determine if ignition was achieved. These size and velocity measurements will allow the determination of disruption and ignition times as functions of drop sizes and ambient conditions.

Turns, S. R.↗

NASA NTRS2007

An Update on the Lithium-Ion Cell Low-Earth-Orbit Verification Test Program

A Lithium-Ion Cell Low-Earth-Orbit Verification Test Program is being conducted by NASA Glenn Research Center to assess the performance of lithium-ion (Li-ion) cells over a wide range of low-Earth-orbit (LEO) conditions. The data generated will be used to build an empirical model for Li-ion batteries. The goal of the modeling will be to develop a tool to predict the performance and cycle life of Li-ion batteries operating at a specified set of mission conditions. Using this tool, mission planners will be able to design operation points of the battery system while factoring in mission requirements and the expected life and performance of the batteries. Test conditions for the program were selected via a statistical design of experiments to span a range of feasible operational conditions for LEO aerospace applications. The variables under evaluation are temperature, depth-of-discharge (DOD), and end-of-charge voltage (EOCV). The baseline matrix was formed by generating combinations from a set of three values for each variable. Temperature values are 10 C, 20 C and 30 C. Depth-of-discharge values are 20%, 30% and 40%. EOCV values are 3.85 V, 3.95 V, and 4.05 V. Test conditions for individual cells may vary slightly from the baseline test matrix depending upon the cell manufacturer s recommended operating conditions. Cells from each vendor are being evaluated at each of ten sets of test conditions. Cells from four cell manufacturers are undergoing life cycle tests. Life cycling on the first sets of cells began in September 2004. These cells consist of Saft 40 ampere-hour (Ah) cells and Lith ion 30 Ah cells. These cells have achieved over 10,000 cycles each, equivalent to about 20 months in LEO. In the past year, the test program has expanded to include the evaluation of Mine Safety Appliances (MSA) 50 Ah cells and ABSL battery modules. The MSA cells will begin life cycling in October 2006. The ABSL battery modules consist of commercial Sony hard carbon 18650 lithium-ion cells configured in series and parallel combinations to create nominal 14.4 volt, 3 Ah packs (4s-2p). These modules have accumulated approximately 3000 cycles. Results on the performance of the cells and modules will be presented in this paper. The life prediction and performance model for Li-ion cells in LEO will be built by analyzing the data statistically and performing regression analysis. Cells are being cycled to failure so that differences in performance trends that occur at different stages in the life of the cell can be observed and accurately modeled. Cell testing is being performed at the Naval Surface Warfare Center in Crane, IN.

Reid, Concha M.↗

NASA NTRS2011

High aspect ratio template and method for producing same for central and peripheral nerve repair

Millimeter to nano-scale structures manufactured using a multi-component polymer fiber matrix are disclosed. The use of dissimilar polymers allows the selective dissolution of the polymers at various stages of the manufacturing process. In one application, biocompatible matrixes may be formed with long pore length and small pore size. The manufacturing process begins with a first polymer fiber arranged in a matrix formed by a second polymer fiber. End caps may be attached to provide structural support and the polymer fiber matrix selectively dissolved away leaving only the long polymer fibers. These may be exposed to another product, such as a biocompatible gel to form a biocompatible matrix. The polymer fibers may then be selectively dissolved leaving only a biocompatible gel scaffold with the pores formed by the dissolved polymer fibers. The scaffolds may be used in, among other applications, the repair of central and peripheral nerves. Scaffolds for the repair of peripheral nerves may include a reservoir for the sustained release of nerve growth factor. The scaffolds may also include a multifunctional polyelectrolyte layer for the sustained release of nerve growth factor and enhance biocompatibility.

Sakamoto, Jeff S.↗

NASA NTRSDate not supplied

In-Situ Alloying of GRCop-42 via Additive Manufacturing: Precipitate Analysis

GRCop-42, a Cu-4at% Cr-2at% Nb alloy, was designed as a high temperature, high strength, high heat flux material for rocket engine combustion chamber liners by NASA Glenn Research Center. In situ alloying of GRCop-42 (ISGRCop-42) using powder bed fusion (PBF) additive manufacturing (AM) takes elemental powders of Cu, Cr, and Nb to be introduced into the PBF environment and develop the GRCop alloy while simultaneously building an AM component. Elemental powders were milled together prior to printing in an effort to facilitate the alloying process. Success of the in situ alloying process may provide lower cost, faster lead times, alloying optimization, and more design freedom in the development of regeneratively-cooled rocket propulsion systems. Evaluation of the ISGRCop-42 was conducted using a phase extraction procedure to isolate the Cr2Nb precipitates from the pure Cu matrix. The isolated precipitates were then examined using x-ray powder diffraction (XRD), scanning electron microscopy (SEM), and energy dispersion spectroscopy (EDS). It was found that ISGRCop-42 successfully and repeatedly formed Cr2Nb at a yield as high as 89% of potential Cr2Nb. Further, it was identified that the preparation of the powder was the most influential factor in alloying success, and the second most influential factor was the laser power.

In Situ alloying↗

NASA NTRS2010

Multifunctional and biologically active matrices from multicomponent polymeric solutions

The present invention relates to a biologically active functionalized electrospun matrix to permit immobilization and long-term delivery of biologically active agents. In particular the invention relates to a functionalized polymer matrix comprising a matrix polymer, a compatibilizing polymer and a biomolecule or other small functioning molecule. In certain aspects the electrospun polymer fibers comprise at least one biologically active molecule functionalized with low molecular weight heparin. Examples of active molecules that may be used with the multicomponent polymer of the invention include, for example, a drug, a biopolymer, for example a growth factor, a protein, a peptide, a nucleotide, a polysaccharide, a biological macromolecule or the like. The invention is further directed to the formation of functionalized crosslinked matrices, such as hydrogels, that include at least one functionalized compatibilizing polymer capable of assembly.

Kiick, Kristi L.↗

NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic composites

Polymer matrix composites (PMCs) offer many benefits for the aerospace industry due to their potential for weight reduction when compared to metal or ceramic based materials. Most PMCs currently in flight use thermoset matrices, however, thermoplastic resins are being explored as alternatives due to their ability to be remelted, which is of particular interest due to the potential for in-situ repair and manufacturing required in space. Most thermoplastic resins are semicrystalline polymers. The properties of semicrystalline thermoplastics are largely influenced by their crystallinity, which can vary due to many factors including thermal treatments, environmental conditions, and mechanical deformation. Monitoring the crystallinity of thermoplastic composites is key to ensuring these materials reliably meet the high demands required by space exploration. This talk discusses the use of multiple techniques such as Polarized Light Optical Microscopy and Fourier-Transform Infrared Spectroscopy to characterize the crystallinity in various thermoplastic composites, including carbon fiber reinforced PMCs and novel bio-based Martian and Lunar regolith composites designed for in-situ manufacturing. This work aims to provide the fundamental data necessary to understand the effects of crystallinity on thermoplastic PMCs, which is key to advancing their use in space applications.

Thermoplastics↗

NASA NTRS1991

Predictions of the critical strain for matrix cracking of ceramic matrix composites

The critical strain for matrix cracking of ceramic matrix composites has been studied; emphasis is placed on the effects of the fiber/matrix debonding length and interfacial debonding energy. Based on a modified shear-lag model, stresses in the fiber and matrix have been found for both the bonded and debonded regions. An energy-balance approach, based upon the stress field, is then adopted to evaluate the critical strain for matrix cracking. From the general equation for the critical strain, close form solutions have been deduced for two limiting cases: complete debonding and perfect bonding. Numerical solutions are given for the cases of nonzero debonding energy and partial fiber debonding. The results show that the interfacial debonding energy, which has been ignored by most of the investigators, is an important factor in determining both the critical strain and the debonding length.

Kuo, Wen-Shyong↗

NASA NTRS2008

Full-field Strain Methods for Investigating Failure Mechanisms in Triaxial Braided Composites

Composite materials made with triaxial braid architecture and large tow size carbon fibers are beginning to be used in many applications, including composite aircraft and engine structures. Recent advancements in braiding technology have led to commercially viable manufacturing approaches for making large structures with complex shape. Although the large unit cell size of these materials is an advantage for manufacturing efficiency, the fiber architecture presents some challenges for materials characterization, design, and analysis. In some cases, the static load capability of structures made using these materials has been higher than expected based on material strength properties measured using standard coupon tests. A potential problem with using standard tests methods for these materials is that the unit cell size can be an unacceptably large fraction of the specimen dimensions. More detailed investigation of deformation and failure processes in large unit cell size triaxial braid composites is needed to evaluate the applicability of standard test methods for these materials and to develop alternative testing approaches. In recent years, commercial equipment has become available that enables digital image correlation to be used on a more routine basis for investigation of full field 3D deformation in materials and structures. In this paper, some new techniques that have been developed to investigate local deformation and failure using digital image correlation techniques are presented. The methods were used to measure both local and global strains during standard straight-sided coupon tensile tests on composite materials made with 12 and 24 k yarns and a 0/+60/-60 triaxial braid architecture. Local deformation and failure within fiber bundles was observed, and this local failure had a significant effect on global stiffness and strength. The matrix material had a large effect on local damage initiation for the two matrix materials used in this investigation. Premature failure in regions of the unit cell near the edge of the straight-sided specimens was observed for transverse tensile tests in which the braid axial fibers were perpendicular to the specimen axis and the bias fibers terminated on the cut edges in the specimen gage section. This edge effect is one factor that could contribute to a measured strength that is lower than the actual material strength in a structure without edge effects.

Littell, Justin D.↗

NASA NTRS2008

Current Computational Challenges for CMC Processes, Properties, and Structures

In comparison to current state-of-the-art metallic alloys, ceramic matrix composites (CMC) offer a variety of performance advantages, such as higher temperature capability (greater than the approx.2100 F capability for best metallic alloys), lower density (approx.30-50% metal density), and lower thermal expansion. In comparison to other competing high-temperature materials, CMC are also capable of providing significantly better static and dynamic toughness than un-reinforced monolithic ceramics and significantly better environmental resistance than carbon-fiber reinforced composites. Because of these advantages, NASA, the Air Force, and other U.S. government agencies and industries are currently seeking to implement these advanced materials into hot-section components of gas turbine engines for both propulsion and power generation. For applications such as these, CMC are expected to result in many important performance benefits, such as reduced component cooling air requirements, simpler component design, reduced weight, improved fuel efficiency, reduced emissions, higher blade frequencies, reduced blade clearances, and higher thrust. Although much progress has been made recently in the development of CMC constituent materials and fabrication processes, major challenges still remain for implementation of these advanced composite materials into viable engine components. The objective of this presentation is to briefly review some of those challenges that are generally related to the need to develop physics-based computational approaches to allow CMC fabricators and designers to model (1) CMC processes for fiber architecture formation and matrix infiltration, (2) CMC properties of high technical interest such as multidirectional creep, thermal conductivity, matrix cracking stress, damage accumulation, and degradation effects in aggressive environments, and (3) CMC component life times when all of these effects are interacting in a complex stress and service environment. To put these computational issues in perspective, the various modeling needs within these three areas are briefly discussed in terms of their technical importance and their key controlling mechanistic factors as we know them today. Emphasis is placed primarily on the SiC/SiC ceramic composite system because of its higher temperature capability and enhanced development within the CMC industry. A brief summary is then presented concerning on-going property studies aimed at addressing these CMC modeling needs within NASA in terms of their computational approaches and recent important results. Finally an overview perspective is presented on those key areas where further CMC computational studies are needed today to enhance the viability of CMC structural components for high-temperature applications.

DiCarlo, James↗

NASA NTRS2011

Optimal Padding for the Two-Dimensional Fast Fourier Transform

One-dimensional Fast Fourier Transform (FFT) operations work fastest on grids whose size is divisible by a power of two. Because of this, padding grids (that are not already sized to a power of two) so that their size is the next highest power of two can speed up operations. While this works well for one-dimensional grids, it does not work well for two-dimensional grids. For a two-dimensional grid, there are certain pad sizes that work better than others. Therefore, the need exists to generalize a strategy for determining optimal pad sizes. There are three steps in the FFT algorithm. The first is to perform a one-dimensional transform on each row in the grid. The second step is to transpose the resulting matrix. The third step is to perform a one-dimensional transform on each row in the resulting grid. Steps one and three both benefit from padding the row to the next highest power of two, but the second step needs a novel approach. An algorithm was developed that struck a balance between optimizing the grid pad size with prime factors that are small (which are optimal for one-dimensional operations), and with prime factors that are large (which are optimal for two-dimensional operations). This algorithm optimizes based on average run times, and is not fine-tuned for any specific application. It increases the amount of times that processor-requested data is found in the set-associative processor cache. Cache retrievals are 4-10 times faster than conventional memory retrievals. The tested implementation of the algorithm resulted in faster execution times on all platforms tested, but with varying sized grids. This is because various computer architectures process commands differently. The test grid was 512 512. Using a 540 540 grid on a Pentium V processor, the code ran 30 percent faster. On a PowerPC, a 256x256 grid worked best. A Core2Duo computer preferred either a 1040x1040 (15 percent faster) or a 1008x1008 (30 percent faster) grid. There are many industries that can benefit from this algorithm, including optics, image-processing, signal-processing, and engineering applications.

Dean, Bruce H.↗

NASA NTRS1993

Protective coatings for high-temperature polymer matrix composites

Plasma-enhanced chemical vapor deposition was used to deposit silicon nitride on graphite-fiber-reinforced polyimide composites to protect against oxidation at elevated temperatures. The adhesion and integrity of the coating were evaluated by isothermal aging (371 C for 500 hr) and thermal cycling. The amorphous silicon nitride (a-SiN:H) coating could withstand stresses ranging from approximately 0.18 GPa (tensile) to -1.6 GPa (compressive) and provided a 30 to 80 percent reduction in oxidation-induced weight loss. The major factor influencing the effectiveness of a-SiN:H as a barrier coating against oxidation is the surface finish of the polymer composite.

Harding, David R.↗

NASA NTRS1964

Three-dimension heat transfer program

An IBM 7094, three dimensional, heat transfer program for satellite application is discussed. The program may be applied to all phases of spacecraft life, from launch to orbital quasi-steady state. Launch phase heating includes inputs by radiation from the hot fairing and free molecule flow heating after nose cone ejection. Orbital heat fluxes are accounted for by direct sunlight, earth-reflected sunlight, and earth-emitted input to the satellite. Internal heat exchange by conduction and radiation is determined, provided the appropriate conductances, radiation view factors, and effective emittances are known. A simplified analysis of an active thermal controlled spacecraft is incorporated into the program. One or more surfaces may contain shutter systems which have optical properties specified as a function of shutter opening. The program evaluates the feasibility of any configuration based upon maintaining an internal component within its tolerable temperature limits. The program employs a matrix inversion subroutine (Gauss Elimination Method) to solve the heat balance equations.

COMPUTER PROGRAM↗

NASA NTRS1972

Manufacturing in space.

Space, in contrast to earth, offers total gravity control and unequaled vacuum, temperature, pressure, and radiation characteristics. In zero-g molecular forces such as cohesion and adhesion become controlling factors even in the largest bulk processes. The absence of relative mass accelerations eliminates the need for support of solid matter. Stability in liquid-solid, liquid-liquid, or liquid-gas mixtures, and the absence of thermal convection is obtained because there is no relative motion in fluids due to differences in density. Applications of these characteristics include liquid-matrix preparation of composites, fine-grain castings, supersaturated alloys, combinations which exhibit liquid-phase immiscibility, the containerless free suspension of materials, surface-tension casting, surface-tension drawing, adhesion casting, and controlled density casting.

Wuenscher, H. F.↗

NASA NTRS1984

Avionics/crew station integration

The U.S. Navy has been encouraging advanced development concepts aimed at increasing the aircraft instrumentation performance for multi-platform applications of 1990's weapons systems. The three areas covered by the Navy's research and development effort are: System Integration, Technology, and Human Factors. The System Integration objectives are to produce a system architecture easily adaptable to many platforms. Technology objectives are to determine the state of the art for displays, electronics, and controls. The Human Factors objectives are to determine the proper human-machine interfaces so that the ultimate crew station will be capable of providing the pilot with the proper display and controls performance to satisfy the diverse requirements of a fighter, attack, ASW, fixed-wing, rotary-wing, and V/STOL platforms in both a one-man crew or two-man crew matrix. All data/control interface among units of this crew station and other platform subsystems will be via digital data buses and video multiplex buses. No individual discrete signal, data, or control lines will be needed. This paper discusses the six interfaces necessary to ensure the optimum development of this crew station, the predicted platform mission improvements, and the requisite life-cycle cost considerations. This concept will serve as a basis for planning the integration of the necessary hardware and software features in current and future weapons systems.

Mulley, W. G.↗

NASA NTRS1993

Linearization of manipulator dynamics using spatial operators

Linearized dynamics models for manipulators are useful in robot analysis, motion planning, and control applications. Techniques from the spatial operator algebra are used to obtain closed form operator expressions for two types of linearized dynamics models, the linearized inverse and forward dynamics models. Spatially recursive algorithms of O(n) and O(n-squared) complexity for the computation of the perturbation vector and coefficient matrices for the linearized inverse dynamics model are developed first. Subsequently, operator factorization and inversion identities are used to develop corresponding closed-form expressions for the linearized forward dynamics model (LFDM). Once again, these are used to develop algorithms of O(n) and O(n-squared) complexity for the computation of the perturbation vector and the coefficient matrices. The algorithms for the LFDM do not require the explicit computation of the mass matrix nor its numerical inversion and are also of lower complexity than the conventional O(n-cubed) algorithms.

Jain, A.↗

NASA NTRS2003

High-Time-Resolution Study of Magnetic Holes in the Solar Wind

The objectives of this investigation are to determine the internal plasma structure of kinetic-scale and larger scale magnetic holes, and to determine their stability, their source mechanism(s), and their spatial extent. It is also of importance to determine the relationship between kinetic-scale holes and long-duration holes. As smaller and smaller magnetic depressions are investigated in order to make this a complete study, a robust criterion is necessary for distinguishing magnetic holes from random or unresolvable fluctuations in the interplanetary magnetic field. In order to resolve this ambiguity, we obtained from the MFI experiments magnetic field measurements from the WIND spacecraft at a time resolution of 46 to 184 ms over certain periods. We have also devised a measure of certainty for magnetic hole detections. The certainty factor, q, is defined as the difference between the mean magnetic field in the hole and the local magnetic field, in units of the local standard deviation of the field strength. For fullest generality, it is necessary to calculate this q over the range of available scales of interest, from 60 ms up to 300 s. This technique establishes a two dimensional matrix of relative probabilities that a hole of some duration (d) might exist in the data set at a given time (t). In identifying q-peaks in time and duration, we also come upon a natural method for distinguishing holes with internal structure from multiple holes in close proximity or holes nested inside of others. If two q-peaks are more than a half-width apart, they are simply said to be separate events.

Lazarus, Alan↗

NASA NTRS1978

Fracture and crack growth in orthotropic laminates

An approximate solution is developed for the determination of the interlaminar normal and shear stresses in the vicinity of a crack in a three dimensional composite containing unidirectional linearly elastic fibers in an infinite linearly elastic matrix. In order to reduce the complexity of the formulation, certain assumptions are made as to the physically significant stresses to be retained. These simplifications reduce the partial differential equations of elasticity to differential-difference equations which are tractable using Fourier transform techniques. The potential for damaged or debonded zones to be generated by an embedded crack is discussed, and stress concentration factors for fibers near the crack are given. Detailed comparisons are made between the present solution, the analogous two dimensional problem, and corresponding shear-lag models.

Goree, J. G.↗

NASA NTRS1991

HITCAN for actively cooled hot-composite thermostructural analysis

A computer code, high temperature composite analyzer (HITCAN), was developed to analyze/design hot metal matrix composite structures. HITCAN is a general purpose code for predicting the global structural and local stress-strain response of multilayered (arbitrarily oriented) metal matrix structures both at the constituent (fiber, matrix, and interphase) and the structural level, including the fabrication process effects. The thermomechanical properties of the constituents are considered to be nonlinearly dependent on several parameters, including temperature, stress, and stress rate. The computational procedure employs an incremental iterative nonlinear approach utilizing a multifactor-interaction material behavior model, i.e., the material properties are expressed in terms of a product of several factors that affect the properties. HITCAN structural analysis capabilities (static, load stepping - a multistep static analysis with material properties updated at each step, modal, and buckling) for cooled hot structures are demonstrated through a specific example problem.

Chamis, C. C.↗